installation manual - thermo pride · 2014. 9. 16. · improper installation, adjustment,...

R-410AOUTDOOR SPLIT-SYSTEM AIR CONDITIONINGMODELS: 18 SEER - CZH / AC8B / AL8B SERIES MODELS: 16 SEER - CZF / AC6B / AL6B SERIES2 TO 5 TONS

INSTALLATION MANUAL

®

TABLE OF CONTENTSGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 5

SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . 17AC CONTROL BOARD FUNCTIONALITY . . . . . . . . . . . . . 18WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

LIST OF FIGURESTypical Installation with Required Clearances . . . . . . . . . . . . . . 3Tubing Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Typical Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Communications Harness Connection . . . . . . . . . . . . . . . . . . . 6Communicating AC with Communicating Air Handler or Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Communicating AC with Non-Communicating Air Handler or Furnace using Communicating Interface Control . . . . . . . . . . 7Thermostat Wiring – Single Stage Air Conditioner (with AC control) – PSC Air Handler . . . . . . . . . . . . . . . . . . . . . . . 8Thermostat Wiring – Single Stage Air Conditioner (with AC control) – VS Air Handler . . . . . . . . . . . . . . . . . . . . . . . 9Thermostat Wiring – Single Stage Air Conditioner (with AC control) – Modulating Furnace . . . . . . . . . . . . . . . . . . . 10

Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . 11Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . 12Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 14Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Single Stage Wiring Diagram (2 - 4 Ton) . . . . . . . . . . . . . . . . 22Single Stage Wiring Diagram (5 Ton) . . . . . . . . . . . . . . . . . . . . 23Two Stage Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

LIST OF TABLESR-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . 18TEST Input Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Operational Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Operational Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Sensor or Switch Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 20Wiring Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION I: GENERALThe outdoor units are designed to be connected to a matching indoorcoil with sweat connect lines. Sweat connect units are factory chargedwith refrigerant for the highest sales volume evaporator plus 15 feet offield supplied lines.Matching indoor coils are available with a thermal expansion valve oran orifice liquid feed sized for the most common usage. The orifice sizeand/or refrigerant charge may need to be changed for some systemcombinations, elevation differences, or total line lengths. See tabulardata sheet provided in unit literature packet for charge requirements.Refer to Application Data covering “General Piping Recommendationsand Refrigerant Line Length” (Part Number 247077).

SECTION II: SAFETYThis is a safety alert symbol. When you see this symbol onlabels or in manuals, be alert to the potential for personalinjury.

Understand and pay particular attention to the signal words DANGER,WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if notavoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation, which, if notavoided may result in minor or moderate injury. It is also used toalert against unsafe practices and hazards involving only property dam-age.

2

INSPECTIONAs soon as a unit is received, it should be inspected for possible dam-age during transit. If damage is evident, the extent of the damageshould be noted on the carrier’s delivery receipt. A separate request forinspection by the carrier’s agent should be made in writing. See LocalDistributor for more information.

Requirements For Installing/Servicing R-410A Equipment• Gauge sets, hoses, refrigerant containers, and recovery systems

must be designed to handle the POE type oils and the higherpressures of R-410A.

• Manifold sets should be 800 PSIG high side and 250 PSIG lowside with 550 PSIG low side retard.

• All hoses must have a 700 PSIG service pressure rating.• Leak detectors should be designed to detect HFC refrigerant.• Recovery equipment (including refrigerant recovery containers)

must be specifically designed to handle R-410A.• Do not use an R-22 TXV.• A liquid-line filter drier is required on every unit.

LIMITATIONSThe unit should be installed in accordance with all National, State, andLocal Safety Codes and the limitations listed below:1. Limitations for the indoor unit, coil, and appropriate accessories

must also be observed.2. Only variable speed air handlers or variable speed furnaces should

be used with these models.3. The outdoor unit must not be installed with any duct work in the air

stream. The outdoor fan is the propeller type and is not designed tooperate against any additional external static pressure.

4. The maximum and minimum conditions for operation must beobserved to ensure a system that will give maximum performancewith minimum service.

5. The unit should not be operated at outdoor temperatures below 65°F without an approved low ambient operation accessory kit installed.

6. The maximum allowable line length for this product is 75 feet.

SECTION III: UNIT INSTALLATIONLOCATIONBefore starting the installation, select and check the suitability of thelocation for both the indoor and outdoor unit. Observe all limitations andclearance requirements.The outdoor unit must have sufficient clearance for air entrance to thecondenser coil, for air discharge, and for service access. See Figure 1"Typical Installation with Required Clearances".

If the unit is to be installed on a hot sun exposed roof or a black-toppedground area, the unit should be raised sufficiently above the roof orground to avoid taking the accumulated layer of hot air into the outdoorunit.Provide an adequate structural support.

ADD-ON REPLACEMENT/RETROFITWhen this unit is being used as a replacement for an R-22 unit, it isrequired that the outdoor unit, indoor coil, and metering device all bereplaced. Line-set change out is also recommended. The followingsteps should be performed in order to insure proper system operationand performance. 1. Change-out of the indoor coil to an approved R-410A coil with the

appropriate metering device.2. Change-out of the line-set when replacing an R-22 unit with an

R-410A unit is highly recommended to reduce cross-contaminationof oils and refrigerants.

3. If change-out of the line set is not practical, then the following pre-cautions should be taken.• Inspect the line set for kinks, sharp bends, or other restrictions,

and for corrosion.• Determine if there are any low spots which might be serving as oil

traps. • Flush the line set with a commercially available flush kit to

remove as much of the existing oil and contaminants as possible. • Install a suction line filter-drier to trap any remaining contami-

nants, and remove after 50 hours of operation. 4. If the outdoor unit is being replaced due to a compressor burnout,

then installation of a 100% activated alumina suction-line filter drieris required, in addition to the factory installed liquid-line drier. Oper-ate the system for 10 hours. Monitor the suction drier pressure drop.If the pressure drop exceeds 3 psig, replace both the suction-lineand liquid-line driers. After a total of 10 hours run time where thesuction-line pressure drop has not exceeded 3 psig, replace the liq-uid line drier, and remove the suction-line drier. Never leave a suc-tion-line drier in the system longer than 50 hours of run time.

Improper installation may create a condition where the operation ofthe product could cause personal injury or property damage.Improper installation, adjustment, alteration, service, or mainte-nance can cause injury or property damage. Refer to this manualfor assistance or for additional information, consult a qualified con-tractor, installer, or service agency.

This product must be installed in strict compliance with theenclosed installation instructions and any applicable local, state,and national codes including, but not limited to building, electrical,and mechanical codes.

R-410A systems operate at higher pressures than R-22 systems.Do not use R-22 service equipment or components on R-410Aequipment. Service equipment Must Be Rated for R-410A.

For multiple unit installations, units must be spaced a minimum of24 inches apart (coil face to coil face).

NOTICE

3

GROUND INSTALLATIONThe unit may be installed at ground level on a solid base that will notshift or settle, causing strain on the refrigerant lines and possible leaks.Maintain the clearances shown in Figure 1 "Typical Installation withRequired Clearances" and install the unit in a level position.Normal operating sound levels may be objectionable if the unit is placeddirectly under windows of certain rooms (bedrooms, study, etc.).Isolate the unit from rain gutters to avoid any possible wash out of thefoundation.

ROOF INSTALLATIONWhen installing units on a roof, the structure must be capable of sup-porting the total weight of the unit, including a pad, lintel, rails, etc.,which should be used to minimize the transmission of sound or vibra-tion into the conditioned space.

UNIT PLACEMENT1. Provide a base in the pre-determined location.2. Remove the shipping carton and inspect for possible damage.3. Compressor tie-down bolts should remain tightened.4. Position the unit on the base provided.

LIQUID LINE FILTER-DRIERThe air conditioning unit’s copper spun filter/dryer is located on the liq-uid line.

TXV INSTALLATIONSThe following are the basic steps for installation. For detailed instruc-tions, refer to the Installation Instructions accompanying the TXV kit.Install TXV kit as follows:1. Relieve the holding charge from the indoor coil by depressing the

Schrader valve stem located in the end of the suction line. Cut thespundown copper to allow installation of the suction line.

2. After holding charge is completely discharged, loosen and removethe schraeder cap seal.

3. Loosen and remove distributor cap seal.4. Install the thermal expansion valve to the orifice distributor assembly

with supplied fittings. Hand tighten and turn an additional 1/4 turn toseal. Do not overtighten fittings.

5. Install the liquid line to the top of the thermal expansion valve with fit-ting supplied with the liquid line. Hand modify the liquid line to alignwith casing opening. Hand tighten the liquid line and an additional1/4 turn to seal.

6. Install the TXV equalizer line into the vapor line as follows:a. Hand tighten the 1/4” SAE nut to the schraeder fitting and an

additional 1/3 turn to seal.7. At this time do not attach sensing bulb. This will be covered later

after brazing of the lines.

PIPING CONNECTIONS

FIGURE 1: Typical Installation with Required Clearances

THERMOSTAT

NEC CLASS 1

WIRING

TO INDOOR

BLOWERNEC CLASS 2

WIRING

TO COIL

WEATHERPROOF

DISCONNECT

SWITCH

24” SERVICE

ACCESS

CLEARANCE

NOTE: ALL OUTDOOR WIRING

MUST BE WEATHERPROOF

SEAL OPENINGS WITH

PERMAGUM OR EQUIVALENT

10” COIL

CLEARANCE AREA

60” OVERHEAD

CLEARANCE

Replacements for the liquid line drier must be exactly the same asmarked on the original factory drier. See Source 1 for O.E.M.replacement driers.

Failure to do so or using a substitute drier or a granular type mayresult in damage to the equipment.

Filter-DrierSource 1 Part No. Apply with Models

029-22195-000 All

NOTICEThis system uses R-410A refrigerant which operates at higher pres-sures than R-22. No other refrigerant may be used in this system.Gauge sets, hoses, refrigerant containers, and recovery systemsmust be designed to handle R-410A. If you are unsure, consult theequipment manufacturer.

Never install a suction-line filter drier in the liquid line of an R-410Asystem. Failure to follow this warning can cause a fire, injury ordeath.

4

The outdoor condensing unit must be connected to the indoor evapora-tor coil using field supplied refrigerant grade copper tubing that is inter-nally clean and dry. Units should be installed only with the tubing sizesfor approved system combinations as specified in tabular data sheet.The charge given is applicable for total tubing lengths up to 15 feet. SeeApplication Data Part Number 247077 for installing tubing of longerlengths and elevation differences.

PRECAUTIONS DURING LINE INSTALLATION1. Install the lines with as few bends as possible. Care must be taken

not to damage the couplings or kink the tubing. Use clean harddrawn copper tubing where no appreciable amount of bendingaround obstruction is necessary. If soft copper must be used, caremust be taken to avoid sharp bends which may cause a restriction.

2. The lines should be installed so that they will not obstruct serviceaccess to the coil, air handling system, or filter.

3. Care must also be taken to isolate the refrigerant lines to minimizenoise transmission from the equipment to the structure.

4. The vapor line must be insulated with a minimum of 1/2" foam rubberinsulation (Armaflex or equivalent). Liquid lines that will be exposedto direct sunlight and/or high temperatures must also be insulated.

5. Tape and suspend the refrigerant lines as shown. DO NOT allowtube metal-to-metal contact. See Figure 2 "Tubing Hanger".

6. Use PVC piping as a conduit for all underground installations asshown in Figure 3 "Underground Installation". Buried lines should bekept as short as possible to minimize the build up of liquid refrigerantin the vapor line during long periods of shutdown

7. Pack fiberglass insulation and a sealing material such as permagumaround refrigerant lines where they penetrate a wall to reduce vibra-tion and to retain some flexibility.

8. See application part number 247077 for additional piping informa-tion.

PRECAUTIONS DURING BRAZING OF LINESAll outdoor unit and evaporator coil connections are copper-to-copperand should be brazed with a phosphorous-copper alloy material suchas Silfos-5 or equivalent. DO NOT use soft solder. The outdoor unitshave reusable service valves on both the liquid and vapor connections.The total system refrigerant charge is retained within the outdoor unitduring shipping and installation. The reusable service valves are pro-vided to evacuate and charge per this instruction.Serious service problems can be avoided by taking adequate precau-tions to ensure an internally clean and dry system.

PRECAUTIONS DURING BRAZING SERVICE VALVEPrecautions should be taken to prevent heat damage to service valvesby wrapping a wet rag around it as shown in Figure 4 "Heat Protection".Also, protect all painted surfaces, insulation, and plastic base duringbrazing. After brazing, cool joint with wet rag.

The valve can be opened by removing the plunger cap and fully insert-ing a hex wrench into the stem and backing out counter-clockwise untilvalve stem just touches the chamfered retaining wall.Connect the refrigerant lines using the following procedure:1. Refer to the Tabular Data Sheet for proper vapor and liquid line siz-

ing.

Using a larger than specified line size could result in oil return prob-lems. Using too small a line will result in loss of capacity and otherproblems caused by insufficient refrigerant flow. Slope horizontalvapor lines at least 1" every 20 feet toward the outdoor unit to facili-tate proper oil return.

FIGURE 2: Tubing Hanger

NOTICE

LIQUID

LINEINCORRECT

CORRECT

TAPE

SHEET METAL

HANGER

INSULATED

VAPOR LINE

FIGURE 3: Underground Installation

Dry nitrogen should always be supplied through the tubing while itis being brazed, because the temperature is high enough to causeoxidation of the copper unless an inert atmosphere is provided. Theflow of dry nitrogen should continue until the joint has cooled.Always use a pressure regulator and safety valve to insure that onlylow pressure dry nitrogen is introduced into the tubing. Only a smallflow is necessary to displace air and prevent oxidation.

This is not a backseating valve. The service access port has avalve core. Opening or closing valve does not close service accessport. If the valve stem is backed out past the chamfered retaining wall,the O-ring can be damaged causing leakage or system pressurecould force the valve stem out of the valve body possibly causingpersonal injury.

Do not leave the system open to the atmosphere. Unit damagecould occur due to moisture being absorbed by the POE oil in thesystem. This type of oil is highly susceptible to moisture absorp-tion.

TO INDOOR

COILTO OUTDOOR

COIL

CAPINSULATED

VAPOR LINE

LIQUID

LINE

PVC

CONDUIT

5

2. Remove the cap and Schrader core from both the liquid and vaporservice valve service ports at the outdoor unit. Connect low pressurenitrogen to the liquid line service port.

3. Braze the liquid line to the liquid valve at the outdoor unit. Be sure towrap the valve body with a wet rag. Allow the nitrogen to continueflowing.

4. Relieve the holding charge from the indoor coil by depressing theSchrader valve stem located in the end of the suction line. Cut thespundown copper to allow installation of the suction line.

5. If TXV has not been installed refer to Page 3 “TXV INSTALLA-TIONS”.

6. Braze the liquid line to the evaporator liquid connection. Nitrogenshould be flowing through the evaporator coil.

7. Slide the grommet away from the vapor connection at the indoor coil.Braze the vapor line to the evaporator vapor connection. After theconnection has cooled, slide the grommet back into original position. a. Install the TXV bulb to the vapor line near the equalizer line, using

the bulb clamp(s) furnished with the TXV assembly. Ensure thebulb is making maximum contact. For detailed instructions, referto the Installation Instructions accompanying the TXV kit.

b. Bulb should be installed on a horizontal run of the vapor line ifpossible. The bulb should be installed on top of the line.

c. If bulb installation is made on a vertical run, the bulb should belocated at least 16 inches from any bend, and on the tubing sidesopposite the plane of the bend. The bulb should be positionedwith the bulb tail at the top, so that the bulb acts as a reservoir.

d. Bulb should be insulated using thermal insulation provided to pro-tect it from the effect of the surrounding ambient temperature.Cover completely to insulate from air-stream.

8. Protect the vapor valve with a wet rag and braze the vapor line con-nection to the outdoor unit. The nitrogen flow should be exiting thesystem from the vapor service port connection. After this connectionhas cooled, remove the nitrogen source from the liquid fitting serviceport.

9. Replace the Schrader core in the liquid and vapor valves.10.Leak test all refrigerant piping connections.

SECTION IV: EVACUATION1. It will be necessary to evacuate the system to 500 microns or less. If

a leak is suspected, leak test with dry nitrogen to locate the leak.Repair the leak and test again.To verify that the system has no leaks, simply close the valve to thevacuum pump suction to isolate the pump and hold the systemunder vacuum. Watch the micron gauge for a few minutes. If themicron gauge indicates a steady and continuous rise, it’s an indica-tion of a leak. If the gauge shows a rise, then levels off after a fewminutes and remains fairly constant, it’s an indication that the systemis leak free but still contains moisture and may require further evacu-ation if the reading is above 500 microns.

2. While system is being evacuated proceed to SECTION V ”ELEC-TRICAL CONNECTIONS”. System charging will be covered underSECTION VI ”SYSTEM CHARGE”

SECTION V: ELECTRICAL CONNECTIONSGENERAL INFORMATION & GROUNDINGCheck the electrical supply to be sure that it meets the values specifiedon the unit nameplate and wiring label.Power wiring, control (low voltage) wiring, disconnect switches, andover current protection must be supplied by the installer. Wire sizeshould be sized per NEC requirements.

The complete connection diagram and schematic wiring label is locatedon the inside surface of the unit service access panel.

FIGURE 4: Heat Protection

The evaporator is pressurized.

In all cases, mount the TXV bulb after vapor line is brazed and hashad sufficient time to cool.

Line set and indoor coil can be pressurized to 250 psig with drynitrogen and leak tested with a bubble type leak detector. Thenrelease the nitrogen charge.

Do not use the system refrigerant in the outdoor unit to purge orleak test.

Never attempt to repair any brazed connections while the system isunder pressure. Personal injury could result.

All field wiring must USE COPPER CONDUCTORS ONLY and bein accordance with Local, National, Fire, Safety, & Electrical Codes.This unit must be grounded with a separate ground wire in accor-dance with the above codes.

NOTICE

NOTICE

6

FIELD CONNECTIONS POWER WIRING1. Install the proper size weatherproof disconnect switch outdoors and

within sight of the unit.2. Remove the screws at the bottom of the corner cover. Slide corner

cover down and remove from unit. See Figure 5 "Typical Field Wir-ing".

3. Run power wiring from the disconnect switch to the unit.4. Remove the service access panel to gain access to the unit wiring.

Route wires from disconnect through power wiring opening providedand into the unit control box.

5. Install the proper size time-delay fuses or circuit breaker, and makethe power supply connections.

FIELD CONNECTIONS CONTROL WIRING(CONVENTIONAL)1. Route low voltage wiring into bottom of control box. Make low volt-

age wiring connections inside the junction box per Figures 9-11“Thermostat Wiring”.

2. The complete connection diagram and schematic wiring label islocated on the inside surface of the unit service access panel.

3. Replace the corner cover and service access panel that wereremoved in Steps 2 and 4 of the ”FIELD CONNECTIONS POWERWIRING” section.

4. All field wiring to be in accordance with national electrical codes(NEC) and/or local-city codes.

5. Mount the thermostat about 5 ft. above the floor, where it will beexposed to normal room air circulation. Do not place it on an outsidewall or where it is exposed to the radiant effect from exposed glassor appliances, drafts from outside doors, or supply air grilles.

6. Route the 24-volt control wiring (NEC Class 2) from the outdoor unitto the indoor unit and thermostat.

FIELD CONNECTIONS CONTROL WIRING(SERIAL COMMUNICATION)1. The Communications Harness is provided with the Touch Screen

Communicating Control.2. Route low voltage four conductor shielded thermostat communica-

tions harness into junction box and connect to communications porton control board. See Figure 6 "Communications Harness Connec-tion".

3. Route low voltage wiring into bottom of control box. Make low volt-age wiring connections inside the junction box per Figures 7-8.

4. The complete connection diagram and schematic wiring label islocated on the inside surface of the unit service access panel.

5. Replace the corner cover and service access panel that wereremoved in Steps 2 and 4 of the “Field Connections Power Wiring”section.

6. Mount the thermostat about 5 ft. above the floor, where it will beexposed to normal room air circulation. Do not place it on an outsidewall or where it is exposed to the radiant effect from exposed glassor appliances, drafts from outside doors, or supply air grilles.

7. Route the 24-volt control wiring (NEC Class 2) from the outdoor unitto the indoor unit and thermostat.

FIGURE 5: Typical Field Wiring

Ambient temperature sensor should extend below corner cover by1”.

Corner

Cover

Control

Wiring

Power

Wiring

Service

Access

Panel

Ambient

Temperature

Sensor

NOTICE

To eliminate erratic operation, seal the hole in the wall at the ther-mostat with permagum or equivalent to prevent air drafts affectingthe operation of the thermostat.

If unit is going to be setup as a communicating system, the conven-tional wiring must be removed from the Outdoor Control Board, ifnot, damage to control board or indoor control could occur.

FIGURE 6: Communications Harness Connection

Ambient temperature sensor should extend below corner cover by1”.

To eliminate erratic operation, seal the hole in the wall at the ther-mostat with Pergamum or equivalent to prevent air drafts affectingthe operation of the thermostat.

NOTICE

COMMUNICATIONS PORT CONTROL BOARD

COMMUNICATIONS

HARNESS

JUNCTION

BOX

NOTICE

NOTICE

7

DEHUMIDIFICATION CONTROLA dehumidification control accessory 2HU06700124 may be used withvariable speed air handlers or furnaces in high humidity areas. Thiscontrol works with the variable speed indoor unit to provide cooling at areduced air flow, lowering evaporator temperature and increasing latentcapacity. The humidistat in this control opens the humidistat contacts onhumidity rise. To install, refer to instructions packaged with the acces-sory and Figures 7-8. Prior to the installation of the dehumidificationcontrol, the jumper across the HUMIDISTAT terminals on the indoorvariable speed air handler or furnace CFM selection board must beremoved.During cooling, if the relative humidity in the space is higher than thedesired set point of the dehumidification control, the variable speedblower motor will operate at lower speed until the dehumidification con-trol is satisfied. A 40-60% relative humidity level is recommended toachieve optimum comfort.If a dehumidification control is installed, it is recommended that a mini-mum air flow of 325 cfm/ton be supplied at all times.

INDOOR CFM CONFIGURATIONFor proper system operation the indoor CFM must be set properly. Refer to the Technical Guide for the outdoor unit for the recommendedair flow settings for each size condensing unit and matching indoor unit.Set the cooling speed per the instructions for the air handler or furnace.Verify the airflow. If installed as a communicating system (outdoor, indoor, and thermo-stat), the system will automatically adjust to the optimal airflow settings.These parameters can also be modified using the Touch Screen Com-municating Control. Refer to the Touch Screen Communicating Controlowner’s manual for this procedure. Manual setting of the airflow on theID equipment is not necessary with the Touch Screen CommunicatingControl.

FIGURE 7: Communicating AC with Communicating Air Handler or Furnace

R

C

Y1

Y2

Touch Screen

Communicating

Control

Air Handler/Furnace

Communicating

Control

Air Conditioner

Communicating

Control

GND

or C

GND

or C

B-

R

A+

GND

or C

GND

or C

B-

R

A+

GND

or C

GND

or C

B-

R

A+

FIGURE 8: Communicating AC with Non-Communicating Air Handler or Furnace using Communicating Interface Control

R

C

Y1

Y2

HUM

W2

DHUM

W

G

C

R

O

Y

Y2

HUM

W2

DHUM

W

G

C

R

O

Y

Y2

Touch Screen

Communicating

Control

Communicating

Indoor

Interface Control

Non-Communicating

Indoor Unit

Air Conditioner

Communicating

Control

Wire per

non-comm.

installation

manual

Assume that

connections

are from

thermostat

GND

or C

GND

or C

B-

R

A+

GND

or C

GND

or C

B-

R

A+

GND

or C

GND

or C

B-

R

A+

8

For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in theProduct Catalog Section.

FIGURE 9: Thermostat Wiring – Single Stage Air Conditioner (with AC control) – PSC Air Handler

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FIGURE 10: Thermostat Wiring – Single Stage Air Conditioner (with AC control) – VS Air Handler

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10

FIGURE 11: Thermostat Wiring – Single Stage Air Conditioner (with AC control) – Modulating Furnace

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11

FIGURE 12: Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces

24VAC Humidifier(Optional)

External Humidistat(Optional)

Open on Humidity Rise

2

C24 – Volt Common

Y1First Stage Compressor

Y2Second StageCompressor

GFan

*PP32U70124

THERMOSTAT

AUXAuxiliary Heat

R24 – Volt Hot(Heat XFMR)

R24 – Volt Hot(Cool XFMR)

C24 – Volt Common



GFan

*DN22U00124

THERMOSTAT

W2Second Stage Heat



E/W1Emergency Heat

E/W1First Stage Heat

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot





2

Connection of the “C”terminal, 24-Volt commonis optional when used with

batteriesThermostat Installer Setup0170-System Type-mustbe set to 8-2 Heat/2 CoolMultistage Conventional

Connection of the “C”terminal, 24-volt commonis optional when used with

batteriesThermostat Installer Setup

1-System Type-mustbe set to 6-2 Heat/2 CoolMultistage Conventional

Thermostat Installer Setup15-Compressor Protection

-must be set to 5

Part Number:S1-2HU16700124

2 Part Numbers:SAP = Legacy

265904 = 031-09169

1

C24 – Volt Common

R24 – Volt Hot

Y1Single Stage Compressor

TWO STAGEVARIABLE SPEED

FURNACE CONTROL

GFan


FURNACE

W/W1First Stage Heat

Y/Y2 Second or Full

Stage Compressor

W2Second Stage Heat

OReversing Valve

X/LMalfunction Light

DHUMDehumidification

1

Move DHUMjumper to “YES”

if humidistat is to be used.

(G/L)*(8/9)V(F/L)*(8/9)V

PV(8/9)ID MODELS

AC 24A Two Stage Air Conditioner – Two Stage Variable Speed Furnace

12

FIGURE 13: Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces

AC 24B Two Stage Air Conditioner – Two Stage Variable Speed Furnace

Connection of the “C”Terminal, 24-Volt Common,is optional when used with

batteries

Part Numbers:SAP = Legacy

265904 = 031-09169

1

C24 – Volt Common

R24 – Volt Hot



FURNACE CONTROL

GFan


FURNACE

W/W1First Stage Heat

Y/Y2 Second or Full

Stage Compressor

W2Second Stage Heat

OReversing Valve


DHUMDehumidification

1

Move DHUMjumper to “YES”


(G/L)*(8/9)V(F/L)*(8/9)V

PV(8/9)ID MODELS

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot








22


2

C24 – Volt Common

R24 – Volt Hot

YFirst Stage Compressor


GFan

*DN22C00124

THERMOSTAT

W2Second Stage Heat

C24 – Volt Common

R24 – Volt Hot



GFan

*DP22U70124

THERMOSTAT

W2Second Stage Heat

Step 1 of Thermostat UserConfiguration Menu must

be set to MS 2

WFirst Stage Heat



batteries

13

FIGURE 14: Thermostat Chart - Two Stage AC – Variable Speed Furnaces

AC 26A Two Stage Air Conditioner – Variable Speed Modulating Furnace

C24 – Volt Common



GFan

*PP32U70124

THERMOSTAT

AUXAuxiliary Heat



C24 – Volt Common



GFan

*DN22U00124

THERMOSTAT

W2Second Stage Heat



E/W1Emergency Heat


TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot



C24 – Volt Common

R24 – Volt Hot


VARIABLE SPEED MODULATING

FURNACE CONTROL

GFan

VARIABLE SPEEDMODULATING

FURNACE

Y/Y2Second or Full

Stage Compressor

HUMDehumidification-


WModulating Heat


171334 = 031-09153

1

1

Move HUMIDISTATjumper to “YES”


FL9CFC9CPC9

ID MODELS






22







-must be set to 5


2

14


AC 26B Two Stage Air Conditioner – Variable Speed Modulating Furnace

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot



C24 – Volt Common

R24 – Volt Hot


VARIABLE SPEED MODULATING

FURNACE CONTROL

GFan

VARIABLE SPEEDMODULATING

FURNACE

Y/Y2Second or Full

Stage Compressor

HUMDehumidification-


WModulating Heat


171334 = 031-09153

1

1

Move HUMIDISTATjumper to “YES”


FL9CFC9CPC9

ID MODELS






22


2

C24 – Volt Common

R24 – Volt Hot



GFan

*DN22C00124

THERMOSTAT

W2Second Stage Heat

C24 – Volt Common

R24 – Volt Hot



GFan

*DP22U70124

THERMOSTAT

W2Second Stage Heat

WFirst Stage Heat



be set to MS 2


batteries Connection of the “C”terminal, 24-Volt commonis optional when used with

batteries

15


AC 31A Two Stage Air Conditioner – Variable Speed Air Handler

C24 – Volt Common



GFan

*PP32U70124

THERMOSTAT

AUXAuxiliary Heat





C24 – Volt Common



GFan

*DN22U00124

THERMOSTAT

W2Second Stage Heat



E/W1Emergency Heat





COM24 – Volt Common

R24 – Volt Hot

W1First Stage Heat

W2Second Stage Heat


Y/Y2Second or Full

Stage Compressor

OReversing Valve

Energized in Cool


HUMHumidity Switch


VARIABLE SPEEDAIR HANDLER CONTROL

GFan

VARIABLE SPEEDAIR HANDLER

1

AVID MODELS

SVMV

EAC (24VAC out)Electronic Air Cleaner

HUM OUT(24VAC out)Humidifier



159481 = 031-09157

1



2


24VACElectronic Air Cleaner

(Optional)

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot



Move the HUM STATjumper to “YES”

if humidistat is to be used. Refer to AH documentation

for W1 and W2 electricheat staging options.


-must be set to 5

16


AC 31B Two Stage Air Conditioner – Variable Speed Air Handler


batteries

C24 – Volt Common

R24 – Volt Hot



GFan

*DN22C00124

THERMOSTAT

W2Second Stage Heat

C24 – Volt Common

R24 – Volt Hot



GFan

*DP22U70124

THERMOSTAT

W2Second Stage Heat


be set to MS 2

WFirst Stage Heat



batteries

COM24 – Volt Common

R24 – Volt Hot

W1First Stage Heat

W2Second Stage Heat


Y/Y2Second or Full

Stage Compressor

OReversing Valve

Energized in Cool


HUMHumidity Switch


VARIABLE SPEEDAIR HANDLER CONTROL

GFan

VARIABLE SPEEDAIR HANDLER

1

AVID MODELS

SVMV

EAC (24VAC out)Electronic Air Cleaner

HUM OUT(24VAC out)Humidifier



159481 = 031-09157

1



2


24VACElectronic Air Cleaner

(Optional)

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot



Move the HUM STATjumper to “YES”

if humidistat is to be used. Refer to AH documentation

for W1 and W2 electricheat staging options.

17

SECTION VI: SYSTEM CHARGE

1. The factory charge in the outdoor unit includes enough charge forthe unit, a 15 ft. line set and the smallest rated indoor coil match-up.Some indoor coil matches may require additional charge. See tabu-lar data sheet provided in unit literature packet for charge require-ments.

2. Once line size/length and indoor coil adders have been figured,weigh in this amount of charge by adding it through the liquid serviceport while the indoor side of the system is still under a vacuum. Thevacuum that is on the indoor side of the system will allow you to addmost of the charge adder. If you are not able to add the full amountthen add the remainder after starting up the system to verify propersubcooling. The subcooling charging method is explained further inthis section.

3. Release the refrigerant charge from the outdoor unit into the system.Open both the liquid and vapor service valves at outdoor unit byremoving the plunger cap and with an allen wrench back out coun-ter-clockwise until valve stem just touches the chamfered retainingwall. ”PRECAUTIONS DURING BRAZING SERVICE VALVE”.

4. Replace plunger cap finger tight, then tighten an additional 1/12 turn(1/2 hex flat). Cap must be replaced to prevent leaks.

5. Use the following subcooling charging method whenever additionalrefrigerant is required for the system charge. A superheat chargingmethod is not suitable for TXV equipped systems.

Measurement MethodIf a calibrated charging cylinder or accurate weighing device is avail-able, add refrigerant accordingly.

Subcooling Charging MethodThis condensing unit must only be used with the matching thermostaticexpansion valve kit listed in the Tabular Data Sheet. This unit must becharged during cooling single stage operation (Y1), second-stage(Y1 & Y2) operation only. Charging should be matched per the subcooling chart located on the rating plate.1. Set the system running in the cooling (Y1) or second-stage (Y1 &

Y2) cooling mode by setting the thermostat at least 6°F below theroom temperature.

2. Operate the system for a minimum of 15-20 minutes.3. Refer to the Tech Guide for the recommended airflow and verify

thisindoor airflow (it should be about 400 SCFM per ton).4. Measure the liquid refrigerant pressure P and temperature T at the

service valve.5. Calculate the saturated liquid temperature ST from Table 1 "R-410A

Saturation Properties".6. Subcooling temperature TC = Saturated Temperature (ST) - Liquid

Temp (T).

Add charge if the calculated subcooling temperature TC in Step 6 islower than the recommended level. Remove and recover the refrigerantif the subcooling TC is higher than the recommended level. See Table 1for R-410A saturation temperatures.After disconnecting manifold gauge set check flare caps on serviceports to be sure they are leak tight. DO NOT OVERTIGHTEN (between40 and 60 inch - lbs. maximum).The “Total System Charge” must be permanently stamped on the unitdata plate.Total system charge is determined as follows:1. Determine outdoor unit charge from tabular data sheet.2. Determine indoor coil adjustment from tabular data sheet.3. Calculate the line charge using the tabular data sheet if line length is

greater than 15 feet.4. Total system charge = item 1 + item 2 + item 3.5. Permanently stamp the unit data plate with the total amount of refrig-

erant in the system.

SECTION VII: INSTRUCTING THE OWNERAssist owner with processing warranty cards and/or online registration.Review Owners Manual, provide a copy to the owner, and provide guid-ance on proper operation and maintenance. Instruct the owner or theoperator how to start, stop, and adjust temperature setting.The installer should also instruct the owner on proper operation andmaintenance of all other system components.

MAINTENANCE1. Dirt should not be allowed to accumulate on the outdoor coils or

other parts in the air circuit. Clean as often as necessary to keepthe unit clean. Use a brush, vacuum cleaner attachment, or othersuitable means.

2. The outdoor fan motor is permanently lubricated and does notrequire periodic oiling.

Refrigerant charging should only be carried out by a qualified airconditioning contractor.

R-410A refrigerant cylinders are rose colored, and have a dip tubewhich allows liquid to flow out of the cylinder in the Upright Posi-tion. Always charge the system slowly with the tank in the uprightposition.

DO NOT attempt to pump “Total System Charge” into outdoor unitfor maintenance, service, etc. This may cause damage to the com-pressor and/or other components. the outdoor unit only has enoughvolume for the factory charge, not the “Total System Charge”.

Compressor damage will occur if system is improperly charged. Onnew system installations, charge system per tabular data sheet forthe matched coil and follow guidelines in this instruction.

Example: The pressure P and temperature T measured at the liquidservice port is 360 Psig and 93°F. From Table 1, the saturated tem-perature for 360 Psig is 109°. The subcooling temperature TC =109°-93°=16°F

18

3. If the coil needs to be cleaned, use clean water to wash dust, dirt,and debris from outdoor condensing coil.

4. Refer to the furnace or air handler instructions for filter and blowermotor maintenance.

5. The indoor coil and drain pan should be inspected and cleaned reg-ularly to prevent odors and assure proper drainage.

SECTION VIII: AC CONTROL BOARD FUNCTIONALITYANIT-SHORT CYCLE DELAYThe control includes a five-minute anti-short cycle delay (ASCD) timerto prevent the compressor from short cycling after a power interruptionor thermostat signal interruption. The ASCD timer is applied when thecontrol is first powered from the indoor unit thermostat and immediatelyfollowing the completion of a compressor run cycle. The compressorand the outdoor fan will not operate during the five minutes that thetimer is active.The ASCD timer can be bypassed by connecting the TEST terminalsfor three seconds while the thermostat is calling for compressor opera-tion (Y1 input signal energized).

LOW VOLTAGE DETECTIONThe control monitors the transformer secondary (24 VAC) voltage andprovides low voltage protection for the AC unit and its components. Inparticular, the control prevents contactor chatter during low voltage con-ditions. If the voltage drops below approximately 19 VAC, the controlwill continue to energize any relays that are already energized but willnot energize any additional relays until the voltage level increases. Ifthe voltage drops below approximately 16 VAC, the control will immedi-ately de-energize the relay outputs and will not energize any relays untilthe voltage level increases. The control will store and display the appro-priate fault codes when low voltage conditions occur.

TEST INPUTThe control includes a TEST input connector that can be used for vari-ous testing functions during installation and service. Table 2 summa-rizes the behavior of the control when the two TEST pins areconnected.

On 5 Ton unit the outdoor fan motor is a permanent magnet DCbrushless type. The motor requires a separate Electronic Control tooperate. Do not attempt to replace this motor with a typical PSCtype. Damage to Electronic Control may result.

DO NOT use coil cleaners to clean outdoor condensing coil. clean-ers containing HF-, hydroxides, chlorides, and sulfates can greatlyreduce the lifetime of the aluminum condensing coil.

NOTICE

NOTICE

Do not connect manifold gauges unless trouble is suspected.Approximately 3/4 ounce of refrigerant will be lost each time a stan-dard manifold gauge is connected.

IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DIS-CHARGE REFRIGERANT INTO THE OPEN AIR DURINGREPAIR, SERVICE, MAINTENANCE OR THE FINAL DISPOSALOF THIS UNIT.WHEN THE SYSTEM IS FUNCTIONING PROPERLY AND THEOWNER HAS BEEN FULLY INSTRUCTED, SECURE THEOWNER’S APPROVAL.

TABLE 1: R-410A Saturation Properties

TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE

PSIG TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE

PSIG TEMP. °F PRESSURE PSIG

45 129.70 60 169.60 75 217.40 90 274.10 105 340.5046 132.20 61 172.60 76 220.90 91 278.20 106 345.3047 134.60 62 175.50 77 224.40 92 282.30 107 350.1048 137.10 63 178.50 78 228.00 93 286.50 108 355.0049 139.60 64 181.60 79 231.60 94 290.80 109 360.0050 142.20 65 184.60 80 235.30 95 295.10 110 365.0051 144.80 66 187.70 81 239.00 96 299.40 111 370.0052 147.40 67 190.90 82 242.70 97 303.80 112 375.1053 150.10 68 194.10 83 246.50 98 308.20 113 380.2054 152.80 69 197.30 84 250.30 99 312.70 114 385.4055 155.50 70 200.60 85 254.10 100 317.20 115 390.7056 158.20 71 203.90 86 258.00 101 321.80 116 396.0057 161.00 72 207.20 87 262.00 102 326.40 117 401.3058 163.90 73 210.60 88 266.00 103 331.00 118 406.7059 166.70 74 214.00 89 270.00 104 335.70 119 412.20

19

LED DIAGNOSTIC INDICATORSThe control includes two LED’s that display diagnostic information.LED1 is red and LED2 is green. These LED’s are used to display oper-ational mode, fault information. A third LED, LED3 is used to displaystatus information. LED3 is yellow. These LED’s are used to displayoperational mode, status, and fault information.

OPERATIONAL MODE DETECTIONThe control can be used in a variety of applications including AC unitswith multistage compressors. The control uses various inputs to deter-mine the proper mode of operation.The control senses the connections that are made to M, M1, and M2terminals and determines the correct operational mode for the control.This is done each time power to the control is cycled. Therefore, it isimportant that no loads be attached to the M1 or M2 terminals of thecontrol for single-stage compressors, and no loads be attached to theM1 terminal of the control for a scroll two-stage compressor.

OPERATIONAL MODE DISPLAYThe control will display its active operational mode using the onboardLED’s when the TEST pins are connected while no thermostat signalsare energized. Table 3 "Operational Mode Display" describes the oper-ational modes. The control will display the operational mode as long asthe TEST pins are shorted and no thermostat signals are energized.When the TEST pin short is removed, the control will return to normalLED displays.

STATUS CODE DISPLAYThe control also provides status codes using the LED’s. Status codesindicate the state of the operation of the unit but do not represent afault. Tables 4 & 5 describes the LED displays during status codes. Sta-tus codes will not be displayed when a fault code is present.

TABLE 2: TEST Input Functionality

Duration of connection (seconds)

Control Behavior with no system master signals present

Control behavior with system master signals present

< 2 No response No response

2 <

Display compressor type TS, Ultratech, or single stage compressor, Ignore LPS

Bypass ASCD (Reduce timer to zero immediately).If Y1 (thermostat or communication) is present and the

high-pressure switch is closed, contactors will be energized.Clear soft lockout Clear soft lockoutClear hard lockout Clear hard lockout

Reset TS anticipation mode counter to zero for TS systems.

Reset TS anticipation mode counter to zero for TS systems.

Reduce TS staging delays for TS systems as described below.

Connection removed Resume normal LED displayConnection not removed Nothing more than previously explained

Do not connect any loads to the M1 or M2 terminals of the controlfor single-stage compressors, and no loads should be attached tothe M1 terminal of the control for scroll two-stage compressor.Incorrect system behavior could result.

TABLE 3: Operational Mode Display

Compressor Type LED1 (Red) LED2 (Green)Single Stage Compressor 1 flash ---TS Compressor 2 flashes ---UltraTech Compressor 3 flashes ---

TABLE 4: Status Code Display

Description Required Condition LED1 (Red) LED2 (Green)No power to control No power to control OFF OFF

First-stage compressor operation – TS or UltraTechTS – M & M1 energized,UltraTech – M energized,Single Stage - NA

OFF ON

Second-stage compressor operation - TS, UltraTech, or Single Stage

TS and UltraTech – M & M2 energized, Single Stage – M energized ON ON

Control normal operation – no communication or call for compressor present No faults active, Y1 or Y2 not present OFF 2s ON / 2s OFF

Control normal operation – in ASCD period No faults active, Y1 or Y2 present, ASCD timer not expired OFF 0.1 sec ON /

0.1 sec OFF

TABLE 5: Status Code Display

Description Required Condition LED3 (Yellow)

Control normal operation – with active communication present System is active and presently communicating successfully. 0.1 sec ON / 0.1 sec OFF

Control powered – without active communication present System has 24 VAC present and the microprocessor is active. 2s ON / 2s OFF

20

FAULT CODE DISPLAYThe control will display any fault code that is currently active using theLED’s. The control will display the fault code, pause two seconds, anddisplay the fault again. The control will continue the fault code displayuntil the condition that caused the fault code no longer exists. If multiplefault codes are present at the same time, the control will display onlythe most recent fault.Table 6 describes the operational faults that the control can detect. Thecontrol displays these types of errors by flashing the LED1 (Red) and/orLED2 (Green).

SENSOR OR SWITCH FAULT CODESTable 7 describes the faults that the control can detect when a problemis present with a sensor or switch. The control displays this type of errorby energizing LED1 (Red) constantly and flashing LED2 (Green).These faults typically occur when an AC unit has been operating and aproblem occurs with a sensor or its wiring. These faults could also occurduring installation as the AC unit is configured.

WIRING RELATED FAULT CODESTable 8 describes the faults that the control can detect when a problemis present with the system wiring or jumper configurations. The controldisplays this type of error by flashing LED1 (Red) and energizing LED2(Green) constantly. These faults typically occur when the AC unit is firstinstalled or when a system component such as the room thermostat orindoor unit is replaced or rewired.

LOCKOUT MODESSoft LockoutThe control will cause a soft lockout during the following conditions.Detailed descriptions of the conditions required for the control to enterthe soft lockout mode are contained in other sections of this document.1. High-pressure switch

a. Two openings within six hours2. Low-pressure switch

a. One opening of the switch for more than five seconds exceptunder certain conditions.

During the soft lockout mode, the control will do the following.1. De-energize the compressor contactor outputs (M, M1, & M2).2. Energize the LED’s with the appropriate flash codes as described

elsewhere in this document.3. In communication applications the fault code will be stored in the

thermostat. (This feature is not available for non communicatingapplications).

The control will reset the soft lockout condition when any of the follow-ing occur following removal of the fault condition.1. Power is cycled to the R or Y1 inputs of the control. This will cause

the soft lockout condition to be reset when the thermostat is satisfiedor when the thermostat is set to SYSTEM OFF and back to HEAT orCOOL mode.

2. The TEST terminals are shorted for more than two seconds.When the soft lockout condition is reset, the control will stop displayingthe fault code and will respond to thermostat inputs normally.

Hard LockoutIf four soft lockouts occur within a twelve-hour period, the control willcause a hard lockout condition. These soft lockouts can be caused bythe same or different conditions. The control will function in the sameway during soft and hard lockout conditions. The difference is in therequirements for resetting the lockout condition. The control will resetthe hard lockout condition when any of the following occur followingremoval of the fault condition.1. Power is removed from the R input of the control.2. The TEST terminals are shorted for more than two seconds.A hard lockout condition will not be reset when the thermostat is satis-fied or when the thermostat is set to SYSTEM OFF and back to HEATor COOL mode. Power (24 VAC) to the control must be removed andreapplied.When the hard lockout condition is reset, the control will de-energizethe LED’s and respond to inputs/communication normally.

Wiring or Setting Related LockoutsThe control will not operate the compressor when the following faultsoccur. These faults can be reset using the same methods used to reseta soft lockout. However, two occurrences of these faults will not cause ahard lockout condition.1. Presence of Y2 thermostat signal without Y1.If a compressor wiring error is detected, the control will not operate thecompressor. Once the compressor wiring error has been detected,power (24 VAC) must be cycled to the control for the control to sensethe wiring change and clear the lockout condition.

TABLE 6: Operational Fault Codes

Description LED1 Flash Code (Red)

LED2 Flash Code (Green)

Control Failure ON OFFOperational FaultsHigh-pressure switch fault (not in lockout yet) 1 OFF

System in high-pressure switch lockout 2 OFF

System in low-pressure switch lockout 4 OFF

Low Voltage (<19.2VAC) preventing further relay outputs 5 OFF

Low Voltage (<16 VAC) stopped current relay outputs 6 OFF

High-pressure switch fault (with no communication for compressor operation and where Y1 and Y2 are not energized)

9 ON

TABLE 7: Sensor or Switch Fault Codes

Description LED1 FlashCode (Red)

LED2 FlashCode (Green)

Outdoor ambient temperature sensor failure (short) ON 1

Outdoor ambient temperature sensor failure (open) ON 2

TABLE 8: Wiring Related Fault Codes

Description LED1 FlashCode (Red)

LED2 FlashCode (Green)

Compressor contactor miswire 1 ONY2 present without Y1 2 ON

21

COOLING OPERATIONFirst-Stage Cooling OperationDuring first-stage cooling operation, the control will receive a thermostatsignal at the Y1 terminal. The control will energize the M compressoroutput terminal. This signal energizes the coil on the compressor con-tactor causing the compressor to run.

Second Stage Cooling OperationDuring second-stage cooling operation, the control will receive a ther-mostat signal from Y1 and Y2 inputs. The control will energize both theM and M2 compressor output terminals. The M signal energizes thecompressor contactor causing the compressor to run. The M2 signalapplies 24VAC to the rectifier plug for the compressor solenoid allowingthe compressor to operate in second stage.

HIGH-PRESSURE SWITCH FAULTThe AC Unit is equipped with a high-pressure switch that is connectedto the control at the HPS terminals. If the high-pressure switch opensfor more than 40 milliseconds, the control will de-energize the compres-sor and store and display the appropriate fault code. If the pressureswitch closes and a thermostat call for compressor operation is present,the control will apply the five-minute anti-short cycle delay timer andstart the compressor when the timer expires. If a call for compressoroperation is initiated while the high-pressure switch is open, the controlwill use the logic associated with a high-pressure switch opening duringa call for compressor operation.

When the compressor is started following a high-pressure switch fault,the control will start a six-hour timer based on accumulated compressorrun time. If the control senses another opening of the high-pressureswitch before the timer expires, it will cause a soft lockout condition.The second opening of the high-pressure switch must be greater than160 milliseconds for the lockout to occur. If the second opening isbetween 40 and 160 milliseconds, the control will de-energize the com-pressor but not cause a soft lockout condition. If the control does notsense a second high-pressure switch opening before the six-hour timerexpires, the timer and counter will be reset.

LOW-PRESSURE SWITCH FAULTThe AC unit is equipped with a low-pressure switch which is connectedto the control at the LPS terminals. If the low-pressure switch opens formore than five seconds, the control will cause a soft lockout conditionand display the appropriate fault codes. If the control experiences multi-ple soft lockouts the control will enter a hard lockout as described inanother section of this document. However, the control will ignore thelow pressure switch input and not cause a soft lockout condition if itopens during the following conditions.

• First two minutes of compressor operation.• While TEST input pins are shorted while any thermostat input Y1

or Y2 signal is being received.

OUTDOOR AMBIENT TEMPERATURE SENSORAmbient temperature sensor is used in communication applicationsonly. It is used to display outdoor temperature to the home owner viathe communicating thermostat.

• Has no effect on operation.• Not required for operation, but a fault code will be displayed when

sensor is not connected or if sensor is shorted.

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SECTION IX: WIRING DIAGRAM

FIGURE 18: Single Stage Wiring Diagram (2 - 4 Ton)

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*-

FIGURE 19: Single Stage Wiring Diagram (5 Ton)

Copyright © 2012 by Johnson Controls, Inc. All rights reserved.

FIGURE 20: Two Stage Wiring Diagram

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Thermo Products, LLC 5235 West State Road 10 North Judson, IN 46366 www.thermopride.com

installation manual - thermo pride · 2014. 9. 16. · improper installation, adjustment,...

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